Remove the engine cover.
Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
Drain the coolant.
(Refer to Cooling System - "Coolant")
Remove the air duct.
(Refer to Intake and Exhaust System - "Air Cleaner")
Remove the battery.
(Refer to Engine Electrical System - "Battery")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
Remove the intercooler inlet pipe & hose (A).
Tightening torque
Clamps :
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
(If equipped with a cap, tighten it until the cap is removed.)
Bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Align the marks of the intercooler pipes/hoses and assembling parts.
Disconnect the intercooler outlet pipe & hose (A).
Tightening torque :
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
(If equipped with a cap, tighten it until the cap is removed.)
Align the marks of the intercooler pipes/hoses and assembling parts.
Disconnect the radiator lower hose (A).
Disconnect the radiator upper hose (A).
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.
Remove the high pressure fuel pipe (A) connecting the high pressure fuel pimp.
(Refer to Engine Control/Fuel System - "High Pressure Pump")
Remove the fuel hoses (A) connecting the high pressure fuel pipe.
(Refer to Engine Control/Fuel System - "High Pressure Pump")
Disconnect the EGR vacuum pipe & hose (A). (Euro 4/5 only)
Remove the air control valve.
(Refer to Engine Control/Fuel System - "Air Control Valve")
Remove the EGR pipe assembly (A).
Tightening torque
Bolts (B) :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)
Bolts (C) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
When installing the EGR pipe assembly, make sure to insert the O-ring (A) to intake manifold before installing EGR pipe (B).
If installing an EGR pipe with O-ring inserted to the intake manifold, the O-ring may be damaged and this can cause an exhaust gas leakage.
Remove the water outlet pipe (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Remove the intake manifold (A) with the gasket.
Tightening torque :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)
When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Be careful not to have a foreign substance come into the inlet port.
Install in the reverse order of removal.
